Stackable Fluid Carton

ABSTRACT

A stackable gable top container and a series of such containers including a top portion, bottom portion and at least one side wall. The top portion including a gable structure having two opposed inclined sides extending away from a peak. The bottom portion including a gable recess for matingly receiving a form substantially matching at least a portion of the gable structure. The at least one side wall extending between the top and bottom portions forming an inner chamber, wherein together the top portion, the bottom portion and the sides walls are capable of retaining a fluid substance within the inner chamber.

TECHNICAL FIELD

The presently disclosed technologies are directed to stackable fluid containers and particularly thermoplastic coated paper containers.

BACKGROUND

Common household drinks, such as milk, juice and other dairy and juice products are often sold in polyethylene coated paper cartons with four flat sides and a gable-style top. U.S. Pat. No. 5,421,512 to Poole discloses one of such contemporary designs. Also, U.S. Pat. No. 6,071,366 to Yamada et al. discloses a similar design. A “gable-style,” as used herein refers to a structure including a triangular top portion with opposed sloped upper surfaces inclined downwardly from a peak ridge. The traditional “gable style” fluid carton has been augmented over the years with the addition of a pouring spout or flip-top lid, as demonstrated in Yamada et al. as well as U.S. Pat. No. 4,964,562 to Gordon or U.S. Pat. No. 5,152,438 to Gordon et al.

Often consumers buy the largest size available of these drink cartons in an effort to reduce costs as well as the number of trips back to the store. However, a half gallon of liquid can weigh too much for small children or people with problems lifting objects approaching the weight of a half gallon. While consumers can try to avoid the weight of such large container by buying multiple smaller containers, multiple smaller containers tend to take up more storage space than a single larger liquid-equivalent container that holds about the same volume of liquid. Also, the peak ridge on gable-style containers makes them un-stackable in a single column, which might otherwise alleviate some of the requirement for needing more storage space. Accordingly, it would be desirable to provide a fluid container design that overcomes these shortcomings of the prior art.

SUMMARY

In accordance with an aspect of the disclosed technologies there is disclosed herein a stackable gable top container including a top portion, bottom portion and at least one side wall. The top portion including a gable structure having two opposed inclined sides extending away from a peak. The bottom portion including a gable recess for matingly receiving a form substantially matching at least a portion of the gable structure. The at least one side wall extending between the top and bottom portions forming an inner chamber, wherein together the top portion, the bottom portion and the sides walls are capable of retaining a fluid substance within the inner chamber.

Additionally, at least one of the two opposed inclined sides can include a closeable pouring spout, wherein the pouring spout when opened provides fluid communication between an inside and an outside of the container. Also the gable recess can include a pouring spout recess, wherein a form substantially matching an exterior form of the pouring spout can be matingly received within the pouring spout recess. The closeable pouring spout can include a removable cap. The peak can include a peak ridge that rises vertically from the two opposed inclined sides. A longitudinal extent of the peak ridge can extend from a first side of the top portion to an opposed second side of the top portion, wherein the longitudinal extent is smaller than an outer width of the bottom portion. Additionally, the gable recess can include two opposed inclined surfaces extending from opposed sides of the bottom portion. The two opposed inclined surfaces can be joined by a peak ridge recess, wherein a form substantially matching an exterior form of the peak ridge can be matingly received within the peak ridge recess. The peak ridge recess can include two opposed planar surfaces that are substantially parallel. Further, at least a portion of the gable recess can be formed by an insert, the insert formed separately from and fixedly secured to the side walls or a part of the bottom portion. Further still, at least a portion of each of the top portion, the at least one side wall and the bottom portion can be formed together from a continuous unitary material.

In accordance with another aspect of the disclosed technologies there is disclosed herein a series of stackable containers including a first container and a second container. The first container including a top portion having a first gable structure. The first gable structure having a peak ridge and two opposed inclined sides extending away from the peak ridge, wherein the peak ridge rises from the two opposed inclined sides vertically. The second container including a bottom portion having a first gable recess for matingly receiving the first gable structure, wherein each of the first and second containers includes an inner chamber capable of retaining a fluid substance therein.

Additionally, at least one of the two opposed inclined sides can include a closable pouring spout, wherein the pouring spout when opened provides fluid communication between an inside and an outside of the first container. The first gable recess can include a pouring spout recess, wherein the pouring spout can be matingly received within the pouring spout recess. The pouring spout can include a removable cap. The peak ridge can extend longitudinally from a first side of the first container top portion to an opposed second side of the first container top portion, wherein the peak ridge longitudinal extent is smaller than an outer width of the second container bottom portion. The first container can include a bottom portion substantially identical to the second container bottom portion. The second container can include a top portion substantially identical to the first container top portion. Also, each of the first and second containers can include external indicia representing a product retained therein, wherein the external indicia on the first container represents a different product from the product represented by the external indicia on the second container. At least one of the first and second containers can be substantially formed from a continuous unitary material. The second container can be mounted atop the first container, whereby the gable structure is matingly secured within the gable recess. Further the series of stackable containers can include a third container, wherein a bottom portion of the third container is substantially identical to the second container bottom portion. The second container can include a top portion substantially identical to the first container top portion, whereby the third container can be mounted atop and matingly received by the second container.

These and other aspects, objectives, features, and advantages of the disclosed technologies will become apparent from the following detailed description of illustrative embodiments thereof, which is to be read in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a set of containers in accordance with an aspect of the disclosed technologies.

FIG. 2 is a side view of two separate containers in accordance with an aspect of the disclosed technologies.

FIG. 3 is a side view of the two containers shown in FIG. 2, in a stacked configuration.

FIG. 4 is a bottom perspective view of two separate containers in accordance with an aspect of the disclosed technologies.

FIG. 5 is a plan view of a cut and scored blank for a container in accordance with an aspect of the disclosed technologies.

FIG. 6 is a perspective view of a lower insert shown in position, with a lower portion of a container including flaps indicated in dashed lines.

FIG. 7 is a cross-sectional side view of an insert in position with a lower portion of a container, with an additional container inserted from below indicated in dashed lines.

FIG. 8 is a plan view of a cut and scored alternative blank for a container in accordance with an aspect of the disclosed technologies.

DETAILED DESCRIPTION

Describing now in further detail these exemplary embodiments with reference to the Figures. In accordance with aspects of the technologies disclosed herein are various aspects of stackable gable-top containers. It should be understood that these containers can be made with varying dimensions and proportions as desired. Thus, only a portion of exemplary containers in accordance with the disclosed technologies are illustrated and discussed herein.

As used herein, terms such as “top”, “bottom”, “vertical”, “horizontal” or related terms refer to the orientations as shown in the accompanying figures. It should be understood that such containers can be tipped, rotated, flipped or otherwise moved into different orientations. Thus, these terms are for reference only and are not intended to limit the disclosure.

FIG. 1 shows a container set 50 of individual stackable containers 10 in accordance with the disclosed technologies. Preferably, the set of containers 50 is sized to match closely to the width and depth of contemporary drink containers, for example the half-gallon, quart or pint of milk or juice that is sold in the United States. Such matching to contemporary drink container dimensions is desirable because many refrigerators and storage devices are designed for commonly sizes containers. Accordingly, one of ordinary skill would understand that the outer dimensions of each container of the set could be altered to achieve similar goals in places or settings where different sizes or units of measure are common. Additionally, the stackable configuration disclosed herein is even suitable for large or smaller sizes. Whether large or small containers, the stacking makes for efficient packaging of multiple containers, as compared to traditional gable-top style containers.

The disclosed technologies are particularly suited to an adaptation of contemporary paper fluid cartons, particularly gable-style cartons as cited above. While cartons generally refer to light cardboard or pasteboard containers, this disclosure is not limited to such materials. In this way, the fluid containers disclosed herein can be made from other known materials to achieve the advantages disclosed herein. Thus, the individual containers 10 can be formed as thermoplastic coated paper cartons, similar to the contemporary cartons described above. However, the containers 10 could alternatively be formed from polymers or more complex composite materials. The container 10 as disclosed herein is intended for retaining fluid substances. As used herein, the expression “fluid substances” means a liquid, gas or mixed substance that is not rigid and generally has no fixed shape or yields easily to external pressure. While a fluid substance can include solids therein, they generally retain the property of being able to flow, change shape and/or move readily when unrestrained.

The container 10 as shown in FIG. 1 includes a top gable structure 20, which is made of two opposed inclined sides 22 and a vertically extending overlap seam that forms the gable peak 24. The inclined sides 22 are generally planar surfaces disposed at an angle relative to the generally planar gable peak 24. It should be understood that the incline angle of the sides 22 could be varied. In fact, a more shallow or steep incline could be formed as desired.

Additionally, shown in FIG. 1 is the pouring spout 26 that includes a screw-on cap. This element is optional, but should be taken into account when designing the form of the bottom mating cavity, discussed further below. An alternative flip-top cap, as disclosed in U.S. Pat. No. 6,071,366 or the like, could similarly be included. In fact, almost any closable pouring spout design could be used, as long as it can be made to fit within the bottom mating cavity. A pouring spout 26 provides fluid communication between an inside and an outside of the container 10. In this way, the contents of the container 10 can enter or be removed from the container. Usually, such pouring spouts 26 are provided to simplify the removal of the fluid contents of the container by pouring. In its simplest form, the pouring spout 26 provides access or a means of access between the inside and the outside of the container.

Generally, the top gable structure 20 also forms a pair of opposed cavities 28. The cavities 28 are a product of the way contemporary designs are made of folded paper, but such cavities 28 do often assist users in handling the container 10 and are thus desirable. However, the cavities 28 could be eliminated to compensate for the fluid capacity lost in forming the bottom mating cavity of each container.

The containers 10 should separate easily from one another. In this way, the containers 10 can be stacked and unstacked with little effort by the end user. An additional sleeve (not shown) could also be provided to hold the set of containers 50 together, at least until the consumer is ready to remove the sleeve and use the products for daily consumption. Such a sleeve could be made of various materials, such as paper, plastic or other suitable material. Also the sleeve could be made substantially solid or in the form of a mesh or net-type structure. The sleeve could alternatively carry informative or promotional material.

As shown in FIGS. 2 and 3, each container 10 is preferably formed with a top gable structure 20 as well as a bottom mating cavity 35. The bottom mating cavity 35 is formed as a recess or depression relative to the bottom edges 30 of each container. The bottom mating cavity 35 is formed by two opposed inner inclined surfaces 32 and a peak recess 34. The bottom mating cavity 35 is also referred to herein as a gable recess. Alternatively, if a pouring spout is included, the gable recess 35 should include a pouring spout recess 36. Thus as shown in FIG. 3, when the two containers 10 are mated together by stacking, the gable recess 35 of the upper container receives the top gable structure 20 of the lower container. In this way, a gable structure 20 of one container can be matingly received by the gable recess 35 of another container. As used herein, the expression “matingly received” means that the two elements when brought together have a good and proper fit together. A snug fit of the gable structure 20 within the gable recess 35 can provide added stability to the containers when stacked.

It should be understood that by forming a gable recess 35, and inner chamber of the container 10 will hold less volume as compared to a contemporary container with a flat bottom. Accordingly, efforts can be made to minimize the size of bottom mating cavity 35, by making the top gable structure 20 smaller. However, the bottom mating cavity 35 preferably has a mating form, such that the top gable structure 20 can be well seated in the gable recess 35 as shown in FIG. 3. Thus, should the top 20 be formed with a more shallow design, such that the inclined sides 22 are inclined less, then the bottom cavity should be formed with a matching inclined for inner surfaces 32. Similarly, it is advantageous to make the rise of the gable peak 24 as small as possible, in order to minimize the size of gable peak recess 34. Alternatively, the peak ridge 24 could be eliminated entirely, especially when the pouring spout 26 is included. Elimination of the peak ridge would allow for the elimination of the gable peak recess 34. One additional way of increasing the inner capacity of container 10, would be to eliminate one or both cavities 28. The elimination of cavities 28 would not require a corresponding modification to the form or shape of the bottom cavity 35.

One consideration when including a pouring spout 26, is that it be positioned such that it does not protrude too far toward a side wall of the container 10. As noted on the lower container 10 shown in FIG. 2, the height h of the pouring spout 26 must not extend too far toward a plane 15 extending vertically from at least one of the side walls of the container. If the pouring spout 26 extends too far (as shown for exemplary purposes on the bottom pouring spout 26 in FIG. 2), then the pouring spout recess 36 cannot be formed within the walls of the container 10. Also, if the far left edge 27 of the pouring spout 26 extends too far, the spout recess 36 will come too close to the side walls of the container making for a weak spot 37. A thickness of the container walls at the weak spot 37 could be designed to be at least a double wall thickness, including the thickness of the outer vertical wall and the thickness of the material forming the surfaces of the bottom cavity 35, particularly the spout recess 36.

FIG. 4 shows a bottom isometric view of two containers 10 separated from one another. The inner side wall 38 of the gable recess 35 is more readily viewable from this angle. It should be understood that while side wall 38 is included on the sides of bottom cavity 35, it need not contain any fluid within or behind that portion of the container. Accordingly, some or all of side wall 38 could be eliminated, perhaps only leaving that portion adjacent the gable peak recess 34. Alternatively, for designs including the pouring spout 26, which provides lateral stability to the stacked containers 10, all or most of the side wall 38 could be eliminated. It should be understood that the side wall 38 provides stability for the stacked set of containers 50 and is thus desirable. Also, side wall 38 provides for a more solid look when multiple containers 10 are stacked, as shown in FIG. 1. Thus for marketing purposes, when displayed as a container set 50, they can appear more like a single contemporary container.

Another aspect of the disclosed technologies, as shown in FIG. 1 is that a set of containers 50 can include individual containers 10 that each contain a different product. Thus, for households that enjoy different kinds of drinks, the set of containers 50 can be sold as a mixed set. For example, one container code holds fat free milk, while another contains whole milk and yet another contains 1% milk (as shown in FIG. 1). Alternatively, two of some containers 10 could hold the same products with a third container 10 holding a different product. In this way mixed and matched sets 50 can be bought and/or sold as desired.

Alternatively, containers for various products each having the common mating structure described herein, would allow an end user to stack the containers 10, taking up less space in the refrigerator, cooler or other means of storage or transport. Also, such common mating structures can assist in stacking numerous containers 10 for shipping or commercial transportation.

As a further alternative, containers 10 could be formed with different heights while maintaining a common mating structure. For example, a single container could be formed that extends as long as the two top containers 10, shown in FIG. 1. In this way, the longer or larger containers could still stack on the smaller size lowest container shown in FIG. 1, or vice versa.

The set of containers 50 in FIG. 1 is preferably formed to collectively match the size and shape of a traditional half or quarter gallon carton and is formed by three individual containers 10. However, it should be understood that the traditional carton size could be divided into a greater or lesser number of cartons. The division of three, as shown in FIG. 1, is merely an exemplary embodiment. Thus, a stackable set of two containers could be sized to equal the size of a traditional half or quarter gallon carton.

As with typical gable-style fluid containers, the major portions of the container 10 can be formed from a continuous unitary material, usually in the form of a web, such as a cardboard sheet. FIGS. 5 and 8 show exemplary container blanks 11, which can be used to form the stackable containers in accordance with the disclosed technologies. The web is cut-out as a blank 11 and is cut C and scored S in order to allow it to be folded and secured to form all or a substantial part of container 10. Based on the orientation in FIGS. 5 and 8, the upper sections X are used to form the top portion including the gable structure; the lower sections Z form the bottom portion including the gable recess; and the central sections Y form the vertical walls. As is customary with gable-style fluid containers, the blank 11 includes four vertical panels with two alternating pairs having the same design. In this way, the four panels form the four vertical sides of the container with the upper and lower portions folding inwardly to close off those respective portions. Also, by alternating the pairs of panels each panel ends-up being disposed directly opposed from its matching pair.

The upper sections X can follow contemporary gable-style container design. Alternatively, the upper sections can be adapted to more closely match the dimensions of the lower gable recess into which it is intended to be matingly inserted. As the lower gable recess is somewhat narrower than the outer width of the container 10, the upper sections X can be modified to fit in the gable recess. FIG. 5 shows trim lines 23 where the flaps that form the upper opposed inclined sides 22 of the gable can be trimmed and made narrower. In this way the inclined sides 22, particularly the uppermost flap 24 that forms the peak ridge, will have a longitudinal extent that is smaller than the outer width of the container bottom 30. A longitudinal extent of the uppermost flap 24 extends from a first side of flap 24 to an opposed second side of flap 24 (horizontally in the figure).

As shown in FIG. 5, the lower section Z includes cuts C and scores S in order to form the gable recess 35, including the peak ridge recess 34. The lateral gable recesses flaps 39 form the gable recess side walls 38. The open portion of the walls 38 is formed by flap 38 b, while flaps 38 c, 38 d get folded over and sealed with adjacent panel flaps 32 b, 32 c. The various flaps formed by the cuts and scores get at least partly folded over one another and then sealed together to form the container as is known in the art. It should be understood that various known bonding and/or sealing techniques can be employed for the final assembly of the container 10.

While the entire container 10 can be formed from a single continuous unitary sheet, alternatively, the container 10 can be formed by adding and joining separate elements. The separate elements could include more than one blank or other pieces. For example, as noted above a closeable pouring spout 26 can be added as taught by the prior art. Additionally, reinforcement material can be added, particularly to the bottom portion to prevent a fluid from leaking out of the container. Such reinforcement can take the form of tape or other thin web material that is bonded to the container walls were needed. Alternatively, an added element can take the form of an insert that forms a portion of the container.

FIG. 6 shows an insert 40 that can be added to form part of the bottom portion of a container 10 (shown in dotted lines). In particular, insert 40 in this embodiment forms a peak recess 34 within the gable recess 35. A preformed insert 40 can be advantageous to avoid the complex folding and flap overlay structure needed to form a gable recess 35, including the peak recess 34. As shown, lower portions 42, 43 of insert 40 directly engage some of the lower section flaps 32 b, 38 b (shown with dotted lines). The alternative blank 11 shown in FIG. 8, is suited for use with insert 40. It should be noted that fewer lateral gable recesses flaps 39 are needed for this embodiment, since the insert 40 completes and closes-off the recessed inner portion of the bottom of container 10. For example, an upper portion 41 of insert 40 completes the upper part of wall 38. The only fold-over of flaps on flaps for this embodiment is between flap 38 c and flap 32 b.

FIG. 7 shows a cross-sectional view of a slightly modified insert 40, which has a more rounded upper tip. It is shown how the inclined flaps 32 b overlap with a lower insert portion 42. These two segments 32 b, 42 can be bonded and/or sealed together as is known in the art. FIG. 7, also shows how the peak ridge recess 44 in the insert 40 is formed to matingly receive the vertically extending gable peak 24 (shown in dotted lines) from another container (the two opposed inclined sides 22 from the other container also shown in dotted lines).

In should be understood that while two exemplary embodiments of insert 40 are shown above in FIGS. 6 and 7, further variations could be employed within the scope of the instant disclosed technologies. For example, the insert 40 could be significantly smaller or larger than that shown. The insert shown in FIGS. 6 and 7 is relatively small as compared to the overall container 10. In this way, a container that includes insert 40, as shown, and even a added plastic pouring spout 26 could still be said to be substantially formed from a continuous unitary material, namely the cardboard blank 11. In this context, “substantially formed” refers to the proportionate area of the container formed by the material in question. Insert 40 could be made larger so that it forms all or almost all of the bottom of the container 10. Such a larger insert 40 could even include vertically extending walls intended for being secured to the container side wall panels in section Y. Also, it should be understood that insert 40 could be made from various materials, including plastic and paper as are used in the gable-top carton industry. Closeable pouring spouts 26 are generally formed from a polymer for precision and durability of features like screw-on caps. In contrast, insert 40 would not require any more durability than traditional paper carton bottoms and could thus be made from paper stock or formed from as a paper product. However, added reinforcement could be desirable. Further, a somewhat larger insert 40 could include pouring spout recess 36 incorporated therein. As yet a further alternative, a separate insert could be added to panel flaps 32 b or other bottom flaps to form the pouring spout recess 36.

It will be appreciated that several of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims. 

1. A stackable gable top container comprising: a top portion including a gable structure having two opposed inclined sides extending away from a peak; a bottom portion including a gable recess for matingly receiving a form substantially matching at least a portion of the gable structure; and at least one side wall extending between the top and bottom portions forming an inner chamber, wherein together the top portion, the bottom portion and the sides walls are capable of retaining a fluid substance within the inner chamber.
 2. The container of claim 1, wherein at least one of the two opposed inclined sides includes a closeable pouring spout, wherein the pouring spout when opened provides fluid communication between an inside and an outside of the container.
 3. The container of claim 2, wherein the gable recess includes a pouring spout recess, wherein a form substantially matching an exterior form of the pouring spout can be matingly received within the pouring spout recess.
 4. The container of claim 2, wherein the closeable pouring spout includes a removable cap.
 5. The container of claim 1, wherein the peak includes a peak ridge that rises vertically from the two opposed inclined sides, wherein a longitudinal extent of the peak ridge extends from a first side of the top portion to an opposed second side of the top portion, wherein the longitudinal extent is smaller than an outer width of the bottom portion.
 6. The container of claim 1, wherein the gable recess includes two opposed inclined surfaces extending from opposed sides of the bottom portion, wherein the two opposed inclined surfaces are joined by a peak ridge recess, wherein a form substantially matching an exterior form of the peak ridge can be matingly received within the peak ridge recess.
 7. The container of claim 6, wherein the peak ridge recess includes two opposed planar surfaces that are substantially parallel.
 8. The container of claim 1, wherein at least a portion of the gable recess is formed by an insert, the insert formed separately from and fixedly secured to the side walls or a part of the bottom portion.
 9. The container of claim 1, wherein at least a portion of each of the top portion, the at least one side wall and the bottom portion are formed together from a continuous unitary material.
 10. A series of stackable containers comprising: a first container including a top portion having a first gable structure, the first gable structure having a peak ridge and two opposed inclined sides extending away from the peak ridge, wherein the peak ridge rises from the two opposed inclined sides vertically; a second container including a bottom portion having a first gable recess for matingly receiving the first gable structure, wherein each of the first and second containers includes an inner chamber capable of retaining a fluid substance therein.
 11. The series of stackable containers of claim 10, wherein at least one of the two opposed inclined sides includes a closable pouring spout, wherein the pouring spout when opened provides fluid communication between an inside and an outside of the first container.
 12. The series of stackable containers of claim 11, wherein the first gable recess includes a pouring spout recess, wherein the pouring spout can be matingly received within the pouring spout recess.
 13. The series of stackable containers of claim 11, wherein the pouring spout includes a removable cap.
 14. The series of stackable containers of claim 10, wherein the peak ridge extends longitudinally from a first side of the first container top portion to an opposed second side of the first container top portion, wherein the peak ridge longitudinal extent is smaller than an outer width of the second container bottom portion.
 15. The series of stackable containers of claim 10, wherein the first container includes a bottom portion substantially identical to the second container bottom portion.
 16. The series of stackable containers of claim 10, wherein the second container includes a top portion substantially identical to the first container top portion.
 17. The series of stackable containers of claim 10, wherein each of the first and second containers includes external indicia representing a product retained therein, wherein the external indicia on the first container represents a different product from the product represented by the external indicia on the second container.
 18. The series of stackable containers of claim 17, at least one of the first and second containers is substantially formed from a continuous unitary material.
 19. The series of stackable containers of claim 10, wherein the second container is mounted atop the first container, whereby the gable structure is matingly secured within the gable recess.
 20. The series of stackable containers of claim 10, further comprising: a third container including a bottom portion substantially identical to the second container bottom portion, wherein the second container includes a top portion substantially identical to the first container top portion, whereby the third container is mounted atop and matingly received by the second container. 